KTM 250 EXC & 300 EXC: known issues, problems & fixes
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- Опубліковано 17 лип 2024
- Own a KTM 250 EXC or 300 EXC, or thinking of buying one? We list the model changes and history, known issues, popular mods and common problems to watch out for. They are great bikes overall so these lists are just a guideline on how to maintain these fine orange beasts! For more info visit crosstrainingenduro.com
250 EXC & 300 EXC HISTORY & MODEL CHANGES
If buying a second hand model, there were minor improvements each year but the significant changes tended to be in 2004, 2008, 2011.
1990 - 1998 KTM 250 / 300 EGS
1999 - start of the 250 / 300 EXC models begin
2004 - lighter engine, about 3kg lighter overall, 36mm carb from 04 on (previously 38mm)
2007 - dual mapping switch on handlebars introduced (e-start on some late 07s)
2008 - electric start, different frame & shock angle reduces twitchy handling
2011 - six speed gearbox, clear fuel tank, new pipe & muffler
2012 - improved bendix for starter motor, different airbox, frame & porting
2013 - DDS clutch with lighter pull, stronger starter motor
2014 - new CDI, battery, jetting, brakes & rear shock. also new head & boysen reeds
but some say a step backwards as it can be hard to get the jetting right
KNOWN ISSUES
- starter motors need regular maintenance & overhauls if used a lot
- low air cleaner box can drown the engine in deep water
- switches on bars unreliable with age unless regularly cleaned
- new bikes are set up too rich and need rejetting
- exhaust pipe guard/bashplate needed if doing a lot of logs or rocks
- stock suspension too soft unless you are a featherweight
- re-route the gearbox breather to avoid getting water in the oil
COMMON MODS
Wet mod for the starter motor
Upgrade to the powerful 2013 starter motor & improved 2012 bendix
Jetting kit
Drop one tooth on the front sprocket
New bikes to a suspension specialist (PDS can be tricky to get right)
Force bashplate / exhaust guard
Force radiator guards
Extend & reroute gearbox breather to avoid water in oil.
dual map ignition and 3different interchangeable power valve springs, head mods
jetting, power valve settings,needle choice,map switch ( 07 and newer), exhaust choice, flywheel weights
pipe guard needed
crap sidestands
service the starter motor
wet mod
upgraded bendix from 2012 that is retro
suspension not so good on earlier ones
99% of Kato electrical problems are usually switch block issues.
I dislike standard KTM switches ADR & start/stop switches, they require pedantic maintenance to retain function after every ride and aren't waterproof.
airbox drowning
jetting from new
2011 went to a six speed box
The 2010 model has a slightly different frame, welded a few mm lower at the headstem which allowed them to rotate the engine forward a tad to improve handling and lower the center of gravity. The 2010 also came with lighter rims than 09, and a slightly different airbox - said to give better spread of dust over the filter and help keep water off it.
Extend and re-route the gearbox breather to a better place to avoid getting water in the oil, water gets in there easily with the stock breather (unless they've fixed this for 2013).
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Great Video!
keep going guys
I have a 2007 KTM 125 EXC and it has been the best bike I've ever owned (even though I've only had 2) but I've ne'er had to make any major repairs to the engine or anything! The only thing that is a problem is that they are bearing killers! I usually change them every 6 months but apart from that I've had no issues with the 7 year old bike! Runs like new!
What bearing exactly?
@@melo5848 turbo encabulator bearing
I got the first 2013 KTM 350 EXC-F in Australia. It's a great bike!
Love it mate! I love my 300 and have done pretty much all of the mods on your list. My starter is dead again though, so I am thinking I will throw the 2013 one in there.
JoeJoe Moto yeah, they definitely aren't designe to last hey? i roughly split it into thirds... e start, clutch start and kickstart.....
Did the 410w starter fix it
@@alienfromarea5115 Sure did mate! It's been going strong since I wrote this comment. However, now it's seems like it's a bit worn.
@@JoeJoeMoto thinking of getting a 410w starter for my husaberg te300
+CROSS TRAINGING ENDURO SKILLS any chance you can provide some insight on whether or not the wet mod has the potential to "cook" or bake the stator? seems a few people have experienced failures with the mod
if you ride hard you need alot of power parts or something similar, as the stock bashplate gets loose quite easly and after that you can lose-it without notice, also stock handguards are not enough, and it would be best to get a 2 stroke bash plate that covers your exhaust also, oh and stock exhaust pipe is way to soft on ktm (stock)
just my 2 cents
Radu Goguta thanks, added some of those to the lists in the video
I know this is old but I have a 2015 exc 300 on 30hrs anything to look out for? and would you suggest a slavens head? im after a bit more grunt. I have a fmf fatty and shorty i do alot of fast desert riding and rocky hill trails with some good climbs. If you have some tips that would be appreciated thanks.
Gas Gas EC 250/300 is a good alternative. They dont have problems with starter motors and are very reliable.
Indy7272 i like the look of the sherco 300 four stroke too, very light....
I picked up a practically brand new 89 250 exc ktm.it has less than 6 hours on the bike, but for some reason,it has no spark. It has the digital ignition. What are the common things that cause that?
I found this video looking for flaws in the 05 200 exc
Any changes from '14 to '15/'16, besides front axle? Rode a 300 yesterday in the woods & loved it. Found a fresh '14 I'm considering. :)
+Older&Wiser i haven't been monitoring it closely but they recently introduced a rear linkage, and it's seems definite there will be a decent starter motor for 2017. that's all i've heard but i'm sure there's more.
In the long run are ktm/husqy 2 strokes gonna go longer between rebuilds than somethjng like a yami kawi or hondy. I’m a 4 stroke guy since I could walk and I’ve never had one break down out in a trail but I’m afraid I’m gonna have a motor blow on a 2t when I’m in buttfuck nowhere and not be able to get the bike outta there. Where I ride if I had a catostropic failure I might have to just leave the bike cuz I can’t get a truck back 45 minutes out In the woods.
Pumpkins always had problems and still have serious issues. My 1997 Adventure 640 wasn`t so reliable..though very cute. New models nothing has changed (except design)
ktm make good starter motors on the thumpers but the two stroke design has been a shocker. they are finally 'fixing' it for 2017 but only time will tell.... ua-cam.com/video/Spj8_hyt1xg/v-deo.html
Chain snap and crank oil seal changed twice I'd love to return or exchange my KTM for something else but it's already out of warranty.
bummer. generally ktm make reliable bikes, or as good as most manufacturers but just with the occasional rubbish design on something like the 2T starter motor.
Generally KTM makes unreliable bikes and their reputation is well known....sometimes you get the lucky model/year and seems like they're all good
Satisfaction Guaranteed funny how you have a suzuki on your profile pic and happen to be talking shit about ktm haha. and by the way if you snap a chain, that has nothing to do with the bike. its just you dont know how to set a chain
i have a 2010 ktm 300 xc and i droped it and i bent the right side subframe is ther anyway to fix it the part is not cheap
but other than that i love my bike
Scoured the net and couldn't find any specific information on the power of a 2003 KTM 250 EXC. Would you know the HP/Kw and ft-lb/N-m? How come its so hard to find power specs on offroad bikes, especially older ones, anyways?
+Xénos Polemistí̱s i think the HP figures are almost totally irrelevant except for drag racing and the top riders in most cases. even looking at a dyno chart its hard to say what it will actually perform like. and poor suspension can lose heaps of power in some cases too. i suspect manufacturers leave the figures out because of their irrelevance to the vast majority of riders like us.
Ah, I see. I am a little disappointed as I was actually looking to buy an '03 250 EXC with big bore kit (293cc I believe) but I just wanted a point of reference for how much power its lost over the years. I was surprised there wasn't a power increase rating listed for the kit because if nothing else, it can be used as a selling point to compare against other brands' big bore kits or improvement over stock performance, which I can find neither rating of. lol Also, I would be using it for drags in the dirt to try and show up my buddies 07/08 wr450f and KLX250(S?) :P
+Xénos Polemistí̱s ah in that case it would be useful if doing drags lol! horsepower is an interesting concept and many don't trust the figures due to the nebulous maths behind it all, whereas torque is more reliable. but you can also get quite different readings on different dynos and different weather conditions so the whole thing has to be taken with a grain of salt.
Xénos Polemistí̱s A
I think that another change important is the frame in 2005.
Did it make it better or worse im looking at getting a 06
@@aussieendurox5262 I had a 02 a 09 and now a 17. The 17 felt on the first ride like Ive never riden any other bike before it just feels so confitable.
But for the differnce on the 02 and 09 i didnt really notice any differnece but im sure the newer the better! (at least for the frames)
Does anyone have any info on the 93 lc4 exc 400? Anything at all would be helpful
Think ive got a complete eng n harness ran when I took it out..maybe it's newer but ..let me know
Never had a two stroke. Currently own a drz400E but i always fancied the 2 strokes. I already know the exc would be better for dirt riding but i dont have the luxury of owning two bikes, so if i get a two stroke i would have to sell my drz.Would a 250 or 300 would be as good for everyday use and occasional 70mile long rides?
doomiz I’m stuck to at present between a 250exc two stroke or the drz400 I also like to nip to work on mine
My 2 stroke 250 Husky sucks up plenty of fuel, after a 60k ride the tank is near empty whilst my DRZ250 used half a tank.
Current dilemma to a T
What do you all think of the 2004 250 xc
never ridden one so can't comment :(
CROSS TRAINING ENDURO SKILLS thanks for taking the time to respond I’m sure its a good bike ktm dosent make bad bikes
I'm going to be buying a 1999 300 exc for just playing around a supermoto track (it already has the wheels). None of the issues here really concern me lol. As long as I do regular maintenance, it should be fine?
don't know marc, this focused more on the models once they got electric starters
What did you pay for the bike?
craken laken £2k, came with off road wheels as well. I had a choice of a 2 years newer 300 exc but it was £700 more and didn't have the supermoto wheels.
Hey mate,
Is there any way we can get in contact with you other then youtube?
YourPalsChrisAndAl you can send messages via youtube
@@crosstrainingenduro help, I. Have a 2017 sxf with a twitchy throttle, too twitchy to ride in woods but not all 250 four strokes have that problem. Nobody has a fix. Got any ideas?
I’m pretty sure the electric start only was from 2009
since 2008*
Any updates?
+Older&Wiser in terms of......?
+CROSS TRAINING, ENDUROCROSS & ENDURO TECHNIQUES New problems or resolutions in the last 18 months since you made this vid?
+Older&Wiser they'll finally fix that dodgy starter motor in 2017 apparently
Im too short for my 125
n. m.
??? Brembo brakes = Brembo brakes!
lol
+John Work ???